浇注机操作说明书.pdf

《浇注机操作说明书.pdf》由会员分享，可在线阅读，更多相关《浇注机操作说明书.pdf（98页珍藏版）》请在淘文阁 - 分享文档赚钱的网站上搜索。

1、2009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-SJob No.:11 19711 197page:1of98OPERATING MANUALOPERATING MANUAL操作手册操作手册Technical documentationTechnical documentation技术资料技术资料PA-20-S Automatic Pouring MachinePA-20-S Automatic Pouring MachinePA-20-SPA-20-S型自

2、动浇注机型自动浇注机DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-STable of contentsTable of contents目录目录1 1Job No.:11 19711 197page:2of98OVERVIEW OF OPERATING ELEMENTS.OVERVIEW OF OPERATING ELEMENTS.7 7总述1.11.21.3POURING CONTROL,GENERALPLC/HARDWARE DESIGN.7SOFTWARE EMPLOY

3、ED.8CONTROL PANEL OVERVIEW.8浇注控制,PLC/硬件总体设计软件的使用控制面板简介2 2MACHINE OPERATIONMACHINE OPERATION.9 9设备运行2.12.22.32.3.12.3.22.3.32.42.4.12.52.5.12.5.2PRINCIPLES OF THE CONTROLS FUNCTIONING.9CONTROLLING THE POURING PROCESS.9OPERATING MODES.10Set-up mode.10Manual mode.10Automatic mode.11ACTIVATING THE MACHI

4、NE.13Activating the machine control.13TASKS BEFORE COMMENCING PRODUCTION.15Weigh empty ladle.15Checking the inoculant container.18控制原理浇注过程控制运行模式调整模式手动模式自动模式激活设备激活设备控制装置生产前的准备工作称重空浇包检查孕育剂箱2009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-S2.5.32.62.6.12.6.22

5、.6.32.6.42.6.52.72.82.92.102.112.122.13Job No.:11 19711 197page:3of98Selecting operation with one ladle option.20REFERENCING THE DRIVES.21Referencing the longitudinal drive.22Referencing the cross drive.26Referencing the tilting drive.31Referencing the turning drive.36Referencing and calibrating the

6、 inoculation drive.40FULLY AUTOMATIC MODE.44LADLE HANDLING AND IRON FEED.47THE MEANING OF THE IRON-FEED SIGNALS.47SEMI-AUTOMATIC MODE(ONLY TILTING DRIVE).48THE MEANING OF THE MACHINE SIGNALS.48PROCEDURE FOR SETTING THE POURING PARAMETERS.49DESCRIPTION AND SETTING OF POURING PARAMETERS.52Setting inst

7、ructions for the pouring parameters.55选择单浇包操作选项参考驱动装置参考径向驱动装置参考横向驱动装置参考倾倒驱动装置参考旋转驱动装置参考和校准孕育剂驱动装置全自动模式浇包处理和铁水进给铁水进给信号的含义半自动模式(仅限于倾倒驱动装置)设备信号的含义设定浇注参数的程序说明和设定浇注参数2.13.12.14浇注参数的设定指导PROCEDURE FOR POURING WITH INOCULANTS.57Inoculation process monitoring.59随流孕育浇注的程序2.14.12.15孕育剂过程监控PROCEDURE FOR POURING

8、 WITH ADDITIONAL POURING.622009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-S伴随补充浇注的程序2.162.17Job No.:11 19711 197page:4of98DESCRIPTION OF POURING ABORTIONS.65SPECIAL FUNCTIONS.67浇注失败的说明特殊功能3 3CONTROL PANEL OPERATING ELEMENTSCONTROL PANEL OPERATING ELEMENT

9、S.7070控制面板操作部件3.13.23.33.43.53.63.73.83.93.103.113.123.133.14EMERGENCY-STOP BUTTON+LAMP(NOS.1 AND2).70BUTTON FOR LIFTING/LOWERING BARRIER1(NO.15).70BUTTON FOR LIFTING/LOWERING BARRIER2(NO.16).71MANUAL/AUTOMATIC SELECTOR SWITCH(NO.4).71SET-UP KEY SWITCH(NO.3).71AUTOMATIC START BUTTON(NO.5).72MUSHROOM

10、 BUTTON SEGMENT DEACTIVATION(NO.6).72ACKNOWLEDGE MALFUNCTION BUTTON(NO.7).72HOOTER BUTTON(NO.12).72HOOTER(NO.11).72CONTROL LAMP FOR GIVING CLEARANCE FOR THE MOULDING SYSTEM(NO.17).73SELECTOR SWITCH FOR GIVING CLEARANCE TO THE MOULDING SYSTEM(NO.18).73CROSS MOVEMENT FORWARDS BUTTON(NO.19).73CROSS MOV

11、EMENT BACK BUTTON(NO.20).74急停开关+报警灯(1号和 2 号)升/降护栏的按钮(15号)升/降护栏的按钮(16号)手动/自动的选择开关(4号)设定的钥匙开关(3号)自动启动的按钮(5号)部分无效的蘑菇开关(6号)确认故障的按钮(7号)报警器的按钮(12号)报警器(11号)移动造型线的控制灯(17号)移动造型线的选择开关(18号)横向移动的前进开关(19号)横向移动的后退开关(20号)2009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-S

12、3.153.163.173.183.193.203.213.223.233.243.25Job No.:11 19711 197page:5of98LONGITUDINAL MOVEMENT FORWARD BUTTON(NO.21).74LONGITUDINAL MOVEMENT BACK BUTTON(NO.22).75PICK-UP LID PICK-UP BUTTON(NO.23).75DEPOSIT LID PICK-UP BUTTON(NO.24).75PRG TILTING DRIVE BUTTON(NO.25).76START POURING BUTTON(NO.26).76P

13、ICK-UP LADLE BUTTON(NO.27).76径向移动的前进开关(21号)径向移动的后退开关(22号)提升盖的提升开关(23号)放置盖的提升开关(24号)PRG倾倒驱动装置的按钮(25号)开始浇注的按钮(26号)提升浇包的按钮(27号)END POUR BUTTON(NO.28).77LIFT LADLE SIGNAL LAMP(NO.29).77JOYSTICK(FIVE-STAGE MASTER SWITCH)(NO.30).78LOWER LADLE SIGNAL LAMP(NO.31).78结束浇注的按钮(28号)提升浇包的信号灯(29号)操纵杆(五级总开关)(30号)降低

14、浇包的信号灯(31号)4 4MONITORING SYSTEMSMONITORING SYSTEMS.7878监控系统4.14.2THE TEMPERATURE MEASURING SENSOR.79CAMERAS.79温度测量传感器摄像头5 5POURING DATA ARCHIVINGPOURING DATA ARCHIVING.7979浇注数据档案6 6DATA EXCHANGE.DATA EXCHANGE.8080数据交换6.1HARDWARE COUPLING.802009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOP

15、ERATING INSTRUCTIONSPA-20-SPA-20-S硬件配合7 7Job No.:11 19711 197page:6of98PLANT CONTROL SYSTEMPLANT CONTROL SYSTEM.8181设备控制系统8 8TELE-SERVICETELE-SERVICE.8181远程诊断9 9BASIC POSITION OF THE POURING MACHINEBASIC POSITION OF THE POURING MACHINE.8181浇注机的初始位置1010LADLE MAINTENANCE.LADLE MAINTENANCE.8282浇包的维护10.

16、1THE LADLES.82浇包1111MACHINE MAINTENANCE.MACHINE MAINTENANCE.8585设备的维护1212EMERGENCY SITUATIONSEMERGENCY SITUATIONS.8888紧急情况1313SAFETY FACILITIESSAFETY FACILITIES.8989安全装置13.1.113.1.213.1.3Barriers 1 and 2.89Safety door at the manual pouring place.90Sequence of safety door functions at the manual pour

17、ing place.90 1号和 2号护栏手动浇注位置的安全门手动浇注位置的安全门功能的1414CHECKLISTCHECKLIST.9393检查清单2009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-SOverview of operating elementsOverview of operating elements总述总述1.1Pouring control,general PLC/hardware design浇注控制,PLC/硬件总体设计Job No

18、.:11 19711 197page:7of98PLCelectronicscabinetPLC 电气柜ET stationelectronicscabinetET 站电气柜ET stationoperatingconsoleET 站操纵台ET stationmachinecabinetET 站设备电气柜Frequency converterMachine cabinet:变频器设备电气柜:-Tilting drive倾倒驱动装置-Longitudinal drive径向驱动装置-Cross drive横向驱动装置-Inoculation drive孕育剂驱动装置Frequency conve

19、rterelectronics cabinet:变频器电气柜:-Turning drive旋转驱动装置2009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-S1.2-Windows XPWindows XP(PC operating system)Windows XP Windows XP(PC 操作系统)-Step 7Step 7(PCL program coding)Step 7 Step 7(PCL 程序译码)-Step 7 TechnologyStep 7

20、 Technology(controlling the Sinamics frequency converter)Step 7 Step 7 技术技术(控制 Sinamics 变频器)-WinCC flexibleWinCC flexible(projecting operating device/touch panel)WinCC flexible WinCC flexible(操作装置/触摸屏)-Graph 7Graph 7(PLC process-control program coding)Graph 7 Graph 7(PLC 过程控制程序译码)-GLS2010GLS2010(vis

21、ualization of the pouring data,process data)GLS2010 GLS2010(浇注数据,过程数据的可视化)-Siwarex FTASiwarex FTA(scales configuration programming)Siwarex FTA Siwarex FTA(比例配置编程)1.3Control panel overviewSoftware employed软件的使用Job No.:11 19711 197page:8of98控制面板简介Control panel(example)控制面板(举例)The main control panel is

22、 for controlling the machines and additional equipments movements andfunctions.主控制面板用于控制设备和附加设备的动作和功能.2009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-S2 2Machine operationMachine operation设备操作设备操作2.1Principles of the controls functioningJob No.:11 19711 1

23、97page:9of98控制原理The automatic pouring machine is employed at moulding plants for the fully automated pouring of grey orspheroidal cast iron components.Here,the ladles with molten iron are tilted by electronically controlledservo motors in such a way that the pouring stream is adapted to the moulds c

24、apacity and the feed funnel isalways kept full.Cameras monitor the light intensity of the molten iron at different points of the pouringprocess and transfer the signals to the tilting drives control.在造型线上使用自动浇注机是为了全自动浇注灰铸铁或者球墨铸铁铸件.通过电子控制的伺服电机将装满铁水的浇包进行倾倒,这样铁水就能根据铸型容积进行调整,浇铸系统始终保持充满的状态.摄像头监控浇注过程不同位置铁

25、水的发光强度并将信号传输给倾倒驱动装置的控制装置.At the beginning of the pouring process,the full pouring ladle is taken from the rotary ladle changer andlifted for the first cast.The visual control system continuously monitors the width of the poured stream andthe levels of iron in the feed funnel and thus determines the

26、optimum tilting angle for each ladle.开始浇注时,装满铁水的浇包从浇包旋转更换装置上取下并略微倾倒准备浇铸第一个铸件.可视控制系统不断地监控铁水流的宽度和浇口杯铁水的液面,这样就能决定每个浇包最佳的倾倒角度.When iron levels rise in the funnel and after the required casting weight has been achieved,the ladle istilted back slightly and is ready for the next cast.当浇口杯内铁水的液面上升,达到预设的铸件重量

27、后,浇包就往回倾倒一些,准备浇注下一个铸型.The ladle changer has been designed as a rotary changer in order to achieve a considerably faster changingtime than those offered by linear changing systems so that production at the foundry is not held up by theprocess of iron replenishment.为了达到比线形更换系统更短的更换时间,浇包更换装置设计为旋转更换装置,这

28、样的话生产就不会因为铁水补充而中断.The machine stands on a rail system with a gear rack enabling precise positioning along the casting line.This means that its possible to use up the molten iron in the event of interruptions to production at thefoundry by emptying the ladle into the stationary moulds.浇注机沿着造型线安装在齿轮齿条

29、精确定位的轨道系统上.如果铸造厂生产突然中断的话,仍然可以用浇包内的剩余铁水浇入到静态的铸型中去.2.2Controlling the pouring process浇注过程控制The pouring process:once pouring has been started in a controlled fashion(start pour 1,2,3),the pouringprocess is controlled in such a way that it is stopped when the desired cast weight and set level have beena

30、chieved.The pouring cameras monitor actual levels in the funnel during the pouring process.If the actuallevel falls below a specified value(set level),the ladle will be tilted more;if the actual level exceeds thespecified level(set level),the ladle will not be tilted as much,it may even be tilted ba

31、ck.浇注过程:一旦浇注机以某种运行模式开始浇铸(开始浇注 1,2,3),浇注过程控制就是当铸件重量和铁水液面达到设定值的时候设备就停止.浇注摄像头监控浇注过程中浇口杯内实际的铁水液面.如果实际的铁水的液面低于指定的液面(预设的液面),浇包就会继续倾倒;如果达到了指定的液面(预设的液面),浇包就不会继续倾倒,而是往回倾倒.2009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-S2.3Next to the are themushroom button(emerge

32、ncy stop)signal lamp(red)(emergency stop)mode-selection switches for manual and automatic modesmushroom button locking(black)(segment deactivation)key switch jogging(set-up mode)push button(black)(automatic start)signal lamp(yellow)(automatic)signal lamp(blue)(basic position)在蘑菇按钮(急停)、信号灯(红色)(急停)旁边是

33、：手动模式和自动模式的模式选择开关蘑菇锁定按钮(黑色)(局部暂停)钥匙开关点动(调整模式)按钮(黑色)(自动启动)信号灯(黄色)(自动)信号灯(蓝色)(初始位置)2.3.1Set-up mode调整模式Operating modes运行模式Job No.:11 19711 197page:10of98(Automatic-manual selector switch)(Automatic-manual selector switch)(自动自动 手动手动 选择开关选择开关)Once the manualmanual mode has been selected using the automa

34、tic manual selector switch,all drives and solenoid valves may be activated by simultaneously using the set-up keyswitch and the operating console in any sequence andwithout any safety interlockingwithout any safety interlocking.一旦使用自动 手动选择开关选择了手动手动模式,所有的驱动装置和电磁阀都会在任何步序和没有安全互锁的状态下同时由调整钥匙开关和操作控制台激活.Th

35、e pouring machines guards will,however,all remain active so that no movement that maybe hazardous to people can be initiated when the guards are open.但是,浇注机的保护装置也全部激活,这是为了保证所有可能造成人身伤害的动作都不会启动.This operating mode was created to prevent operation using the valves emergency functions(dangerous erroneou

36、s switching possible).建立这种操作模式是为了防止利用控制阀的应急操作(有危险错误的可能).2.3.2Manual mode手动模式(Automatic-manual selector switch)(Automatic-manual selector switch)(自动自动 手动手动 选择开关选择开关)ManualManual mode allows all drives with solenoid valves to be activated with the restriction thathazardous movementshazardous movements

37、 will be prevented by thesafety interlocking systemsafety interlocking system.2009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-SJob No.:11 19711 197page:11of98手动手动模式允许所有带电磁阀的驱动装置都可以在由安全互锁系统防止造成人身伤害的状态下激活.Drives that have reached their end positions will al

38、so be switched to self-retentionself-retention in thismode.在这种模式中,当驱动装置到达最终位置时也能由自我保持自我保持控制.This prevents the devices from leaving their positions in the event of leaks in the hydraulicssystem.这样能防止在液压系统渗漏的情况下这些装置偏离位置.Manual operationsManual operations自动模式In order to move the individual drives by ha

39、nd为了用手动方式分别移动的驱动装置This segment is stopped by the segment deactivation mushroom button这个区域由局部暂停蘑菇按钮停止；The automaticautomatic manual selector switch on the HvO will be set to manual manual selector switch on the HvO will be set to manual.在在 HvOHvO 控制面板上的控制面板上的 自动自动 手动手动 选择开关将设定为选择开关将设定为 手动手动；Now the d

40、esired drives may be selected in the menu and moved with the correspondingbuttons.The drive will stop when the button is released during the movement.现在可以在菜单中选择所需要的驱动装置并使用有关的按钮动作.在运动过程中,释放按钮时动作就将停止.To return to automatic mode回到自动模式the mushroom button must be released必须释放蘑菇按钮；the automatic manual sel

41、ector switch must be set to automatic 自动 手动 选择开关必须设定为自动；automatic mode for this segment is started with the start automatic button.这个区域的自动模式由自动模式启动按钮启动；This also indicates whether and how the drives valves are controlledandand in which positionthe drives are located.这也同时显示了驱动装置的控制阀是否处于控制和如何控制的情况,以及这

42、些驱动装置所处位置.2.3.3Automatic mode自动模式(Automatic-manual selector switch)(Automatic-manual selector switch)(自动自动 手动手动 选择开关选择开关)ATTENTION!ATTENTION!注意注意!BeforeBefore startingstarting thethe mouldingmoulding system,system,makemake suresure thatthat neitherneither peoplepeople nornor objectsobjects areareloc

43、ated within the plant.located within the plant.在启动造型线之前在启动造型线之前,必须确保在设备内部没有人员和其他物品必须确保在设备内部没有人员和其他物品.2009-02-06DOCUMENTATIONDOCUMENTATIONOPERATING INSTRUCTIONSOPERATING INSTRUCTIONSPA-20-SPA-20-SJob No.:11 19711 197page:12of98Checks must also be carried out to determine whether damage that could imp

44、air plantChecks must also be carried out to determine whether damage that could impair plantoperationoperation oror posepose risksrisks toto peoplepeople hashas beenbeen causedcaused toto thethe plantplant sincesince it it waswas lastlast ininoperation.operation.必须检查是否有造成设备损坏和导致人身伤害的动作必须检查是否有造成设备损坏和

45、导致人身伤害的动作,因为在生产过程中这些动作会一因为在生产过程中这些动作会一直进行直进行.AutomaticAutomatic modemode is selected by positioning the automatic manual selector switch toautomatic and then activated when the start automatic button is pressed.将自动 手动 选择开关选择自动模式自动模式,然后按下自动模式启动按钮激活.A warning signal(siren)will be sounded when the auto

46、matic system is activated.The pouringmachine will commence to operate independently once this signal has stopped.激活自动系统时报警信号(报警器)会发出鸣叫.这种鸣叫停止后浇注机将自行开始工作.Automatic operation is indicated by signal lamps on the control panel(continuous lightcontinuous light)andan all-round lamp in the pouring machines

47、 segment.控制面板上的信号灯(连续灯连续灯)和浇注机的旋转灯表示设备处于自动模式.NOTE:NOTE:注意：注意：In the event of a malfunction caused by a limit-switch monitor indicating parityparity(e.g.positiontop and position bottom are both occupied),it will not be possible to initiate automatic mode.The error must be remedied and the malfunction

48、 acknowledged(on the console).如果限位开关引起的故障在显示屏上显示对称(例如同时处于位置的顶部和底部),那就不能启动自动模式.必须纠正和确认故障(在控制台上).The tilting drive segment may be switched to semi-automatic using the tilting drive(PRG)button.倾倒装置可以使用tilting drive(PRG)按钮转换到半自动模式.The tilting drive segment may be moved semi-automatically using various b

49、uttons.This includes,forexample,start pouring or tilting back.倾倒装置可以使用不同的按钮进行半自动操作.这包括,例如,开始浇注或者倾倒退回.It is only possible to switch from fully automatic to semi-automatic when a pouring sequence has beencompleted.Pressing the PRG button will initially only request semi-automatic execution.This state

50、isindicated by flashing at a frequency of 2 Hz(rapid flashing)of the corresponding light signal.If semi-automatic mode is activated at the end of the machine cycle,the corresponding signal lamp will indicatethis with a flashing frequency of 1 Hz(slow flashing).The signal lamp will light up continuou